The Best of Both Worlds
July 2002
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By combining flexo and gravure, Sonoco is able to maintain its competitive edge.
By Kate Tomlinson, Associate Editor
IN 1993, SONOCO'S Flexible Packaging division realized that it could offer customers the value-added products many were looking for, by expanding its strictly gravure process base. Today, with nine plants worldwide, Sonoco achieves its range of graphics by running flexo and gravure both separately and in combination.
Sonoco's extensive equipment roster includes: wide- and narrow-web rotogravure presses, up to 11 stations with in-line lamination and cold/heat seal coatings; wide- and narrow-web flexographic presses, up to 10 stations with in-line lamination and cold/heat seal coatings; gravure/flexo combination presses; off-line adhesive and extrusion lamination; stand-up pouch, shrink film, and label capabilities.
"Like many flexible packaging companies, Sonoco began as a gravure printer," says Director of Technology, Jeff Schuetz. "But as our customers asked us to provide a larger share of their packaging needs, we decided it was time to add flexography to our capabilities. It has proven to be one of our wiser choices, as today, flexo holds about 50 percent of our North American market share. We also have a number of presses that are capable of combination gravure and flexo printing."
Eddie Smith, vice president of Sonoco's Flexible Packaging division, explains that while flexo meets (and often exceeds) the needs for most packages, gravure is still necessary for accuracy.
"Using a gravure head on the back end of a flexo press is fairly standard," he says. "We typically use it to apply cold seal coatings. The most common use for the flexo stations on our gravure platforms is to offer flexibility so customers get the benefit of gravure's high-end graphics with lower cost flexographic copy where appropriate."
Getting it done with gravure
Some of the hottest packages on store shelves are currently being run on gravure presses. Makers of everything from candy and crackers to cat food and tuna fish, are turning to this process to ensure their products have optimal appeal and shelf life.
One of the most popular packages currently available is the pouch. Whether purchasing soup or tuna in a retort pouch or snacks in a stand-up, this package offers many advantages. The most recent pouch trend is the window, which allows the consumer to see the food. According to Rick Morse, Sonoco's director of marketing, pouches are doing wonders for the food service and single-serve markets.
"Pouches are generally easy for the consumer," Morse says. "They open easily; are light weight; tend to leak less (as opposed to cans); can visually be bigger and brighter; many are resealable; and most importantly, if dealing with retort pouches, the food tastes better because it is cooked less before being sent to stores."
By Kate Tomlinson, Associate Editor
IN 1993, SONOCO'S Flexible Packaging division realized that it could offer customers the value-added products many were looking for, by expanding its strictly gravure process base. Today, with nine plants worldwide, Sonoco achieves its range of graphics by running flexo and gravure both separately and in combination.
Sonoco's extensive equipment roster includes: wide- and narrow-web rotogravure presses, up to 11 stations with in-line lamination and cold/heat seal coatings; wide- and narrow-web flexographic presses, up to 10 stations with in-line lamination and cold/heat seal coatings; gravure/flexo combination presses; off-line adhesive and extrusion lamination; stand-up pouch, shrink film, and label capabilities.
"Like many flexible packaging companies, Sonoco began as a gravure printer," says Director of Technology, Jeff Schuetz. "But as our customers asked us to provide a larger share of their packaging needs, we decided it was time to add flexography to our capabilities. It has proven to be one of our wiser choices, as today, flexo holds about 50 percent of our North American market share. We also have a number of presses that are capable of combination gravure and flexo printing."
Eddie Smith, vice president of Sonoco's Flexible Packaging division, explains that while flexo meets (and often exceeds) the needs for most packages, gravure is still necessary for accuracy.
"Using a gravure head on the back end of a flexo press is fairly standard," he says. "We typically use it to apply cold seal coatings. The most common use for the flexo stations on our gravure platforms is to offer flexibility so customers get the benefit of gravure's high-end graphics with lower cost flexographic copy where appropriate."
Getting it done with gravure
Some of the hottest packages on store shelves are currently being run on gravure presses. Makers of everything from candy and crackers to cat food and tuna fish, are turning to this process to ensure their products have optimal appeal and shelf life.
One of the most popular packages currently available is the pouch. Whether purchasing soup or tuna in a retort pouch or snacks in a stand-up, this package offers many advantages. The most recent pouch trend is the window, which allows the consumer to see the food. According to Rick Morse, Sonoco's director of marketing, pouches are doing wonders for the food service and single-serve markets.
"Pouches are generally easy for the consumer," Morse says. "They open easily; are light weight; tend to leak less (as opposed to cans); can visually be bigger and brighter; many are resealable; and most importantly, if dealing with retort pouches, the food tastes better because it is cooked less before being sent to stores."
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